Method for making a dashboard subassembly in paticular a motor vehicle dashboard console

ABSTRACT

The invention concerns a method for making a dashboard subassembly comprising electrical and/or electronic components ( 1 ) connected to conductors ( 2 ) and attached to a rigid support ( 3 ). The invention is characterized in that it consists in: providing a flexible mat ( 4 ) provided with said conductors ( 2 ); mounting said components ( 1 ) on said mat ( 4 ), connected to said electrical conductors ( 2 ); rigidizing said mat ( 4 ) by overmoulding it with a material designed to form said support ( 3 ). The invention also concerns a dashboard subassembly, in particular a motor vehicle dashboard console, obtained by said method.

FIELD OF THE INVENTION

The invention relates to a method of manufacturing a dashboardsub-assembly, and a dashboard sub-assembly, especially avehicle-dashboard console, obtained by such a method.

BACKGROUND OF THE INVENTION

Currently, in vehicle dashboards, it is known to provide, in a partcalled console situated in its central region, a certain number ofequipment items intended to constitute an interface between the users,principally the driver and the front passenger, and elements to becontrolled such as heating, ventilation and/or air-conditioning devices,or others.

To do this, such sub-assemblies include electrical and/or electroniccomponents, connected to conductors and fixed to a rigid supportgenerally consisting of the body of the console.

The said electrical and/or electronic components serve, especially, todefine changeover switches for the control of equipment items, indicatorlamps and/or displays for the visual display of information. They mayfurthermore be computers, memories or other electronic components,mounted or not mounted on electronics cards.

To date, the wiring of the said components is carried out using wirescut to the required length and equipped with connection terminals, thesewires being bundled together in the form of strands using adhesivetapes, tubular sleeves made of flexible plastic, these possibly beingheat-shrinkable. The connection terminals are grouped together injunction boxes.

It is appreciated that this design is not well suited to variants anddoes not integrate the individual components. It is therefore expensiveand its reliability is too often insufficient.

SUMMARY OF THE INVENTION

The object of the present invention is to propose a method ofmanufacturing a dashboard sub-assembly, and a dashboard sub-assembly,especially a vehicle-dashboard console, which overcome the drawbacksmentioned above and which permit a more integrated design in such a wayas to reduce the number of the pieces and of the assembly operations.

Another object of the present invention is to propose a method ofmanufacturing a dashboard sub-assembly, and a dashboard sub-assembly,especially a vehicle-dashboard console, the reliability of which isimproved.

Another object of the present invention is to propose a method ofmanufacturing a dashboard sub-assembly, and a dashboard sub-assembly,especially a vehicle-dashboard console, which make it possible toimprove the protection of the electrical and/or electronic componentsused.

Other objects and advantages of the invention will appear during thedescription which will follow, which is given only by way of example andwhose aim is not to limit the invention.

The invention first of all relates to a method of manufacturing adashboard sub-assembly, comprising electrical and/or electroniccomponents, connected to electrical conductors and fixed to a rigidsupport, characterised by the fact that, according to the said method:

-   -   a flexible web is provided, equipped with the said conductors,    -   the said components are mounted on the said web, in connection        with the said conductors,    -   the said web is stiffened by over-moulding it with a material        intended to constitute the said support.

According to an advantageous embodiment of the invention, interfacemeans are defined with the said electrical components and the materialof the said rigid support, provided locally modified and/or deformed inthe region of the said components.

The invention also relates to a dashboard sub-assembly, especially avehicle-dashboard console, obtained by the manufacturing methoddescribed above.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood on reading the followingdescription, accompanied by the attached drawings which form an integralpart of it and among which:

FIG. 1 describes, in a rear view, an embodiment example of the dashboardsub-assembly according to the invention,

FIG. 2 is a view in section illustrating a first detail of an embodimentexample of the dashboard sub-assembly according to the invention,

FIG. 3 illustrates, in a partially cut-away perspective view, a seconddetail of an embodiment example of the dashboard sub-assembly accordingto the invention,

FIG. 4 is a view in section illustrating in a complementary manner thedetail represented in the preceding FIG. 3,

FIG. 5 is a view in section illustrating a fourth detail of anembodiment example of the dashboard sub-assembly according to theinvention,

FIG. 6 illustrates an embodiment variant of the detail represented inthe preceding FIG. 5,

FIG. 7 illustrates, in front view, a part of an embodiment example ofthe dashboard sub-assembly, according to the invention, using theelement detailed in FIG. 2,

FIG. 8 illustrates, in front view, a part of an embodiment example ofthe dashboard sub-assembly, according to the invention, using theelement detailed in FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention first of all relates to a method of manufacturing adashboard sub-assembly.

As illustrated in the various figures, the dash-board sub-assemblyobtained by the manufacturing method according to the inventioncomprises electrical and/or electronic components 1 connected toelectrical conductors 2 and fixed, for example continuously, to a rigidsupport 3.

According to the invention, a flexible web 4 equipped with the saidconductors 2 is first of all provided. The conductors are, especially,conductors for supplying power and/or for the circulation ofinformation, for example digital information, to the said components 1.Three of the said conductors 2 are provided, in particular, two forsupplying power and one for the circulation of information, arrangedparallel to one another along the said web. They are fixed to the lattercontinuously, for example, and are possibly covered with a strip ofelectrically insulating material.

Still according to the invention, the said components 1 are mounted onthe said web 4, in connection with the said electrical conductors 2,then the said web 4 is stiffened by over-moulding it with a materialintended to constitute the said support 3. Thus a solution presenting animproved level of integration is made available.

By “over-moulding” it is understood that the said support 3 comesface-to-face with one of the faces of the said web 4, substantially overall of its surface, the said support 3 and the said web 4 being fixed toone another at least by the effect of the bulk setting, during themoulding, of the material constituting the support 3. Of course,materials making it possible to strengthen the adhesion can be used.

The said electrical and/or electronic components 1 consist, for example,of computers and/or of memories. They may also be other types ofelectrical and/or electronic components.

On this subject, according to an advantageous embodiment of theinvention, illustrated in FIGS. 2, 3, 4 and 6, interface means 5 aredefined with at least one part of the said components 1 and the materialof the said rigid support 3. To do this, the material of the saidsupport is modified and/or deformed locally, before stiffening, in theregion of the said components 1.

The said interface means are intended, especially, to permit a dialoguewith the user, for example, by virtue of means for control by changeoverswitching and/or by visual-display means. They may also be intended,especially, to allow exchanges with external electrical and/orelectronic circuits, for example by the circulation of supply currentand/or of data. It will thus be possible to designate some of the saidcomponents 1 to form the changeover-switching and/or visual-displaymeans.

According to such a solution, interface means such as indicator lamps,changeover switches and/or connection boxes are made available in thisway, which are produced at least in part in the bulk of the said support3.

The said web 4 is provided, for example, face-to-face with the face ofthe said support 3, called rear face 6, opposite that intended to beoriented towards the users, called front face 7.

As is more particularly illustrated in FIGS. 2 to 4, at least some ofthe components 1 and/or of the said conductors 2, for example, aredesigned to be between the said web 4 and the said support 3, againstthe said rear face 6 of the latter. They are thus sandwiched between theweb 4 and the material of the said support 3 and protected. Thecomponents in question are especially those of the interface means 5intended for the changeover switching and/or the visual display.

The said components, especially for changeover switching and/or visualdisplay, may therefore be made visually and/or mechanically accessiblevia the front face 7, of the said support 3, opposite the rear face 6 ofthe latter.

As is more particularly illustrated in FIG. 2, the material intended toconstitute the said rigid support 3 is, for example, made translucent inplaces to allow light to pass through the thickness of the said support,especially in the region of the components 1 intended to formvisual-display means.

The latter consist, especially, of electro-luminescent components suchas light-emitting diodes 8. The said diodes are, especially, soldered tothe said conductor 2.

Pictograms 9, for example produced by laser etching or other means, mayfurthermore be provided face-to-face in the region of the front face 7of the said rigid support 3.

As is more particularly illustrated in FIGS. 3 and 4, it is alsopossible to produce, locally, at least one orifice 10 opening out in thethickness of the said rigid support 3, between its front face 7 and itsrear face 6, especially in the region of the components 1 intended toform changeover-switching means.

Switching means are then furthermore installed in the region of the saidorifices 10, the said switching means being made able to interact, forthe changeover switching, with the walls of the said orifice 10.

The said components 1 for the changeover switching consist, for example,of a discontinuity in the conductors 2, linked to conducting studs 11,defining two terminals intended to interact with the said switch means.

The latter consist, especially, of bubble membranes 12, that is to say,of a conducting strip 13, able to connect the said studs 11, and ofpressure means 14, on the said strip 13. The said pressure means aredesigned to be electrically insulating and the said strip 13 is designedto be deformable so as to be able to pass from a first position in whichit is held by the said pressure means 14 against the said studs 11 to asecond position in which it is no longer in contact with the said studs11, and vice-versa. The said pressure means are guided by the walls ofthe said orifice 10.

It is also possible to designate at least some of the components of theinterface means 1 for connection to external circuits.

To do this, as is more particularly illustrated in FIG. 5, according toa first embodiment example, it is possible to use a said component 1consisting of a junction box, known to the person skilled in the art andheld by the said rigid support 3.

As is more particularly illustrated in FIG. 6, according to anotherembodiment, the following stages are carried out:

-   -   a protuberance 15 intended to be covered at least partly by a        fold 16 of the said flexible web 4 is formed with the material        of the said support 3,    -   the said conductors 2 are made able to establish an electrical        connection in the region of the said fold 16, especially by        surface contact by virtue of localised baring of these        conductors,    -   mechanical fastening means 17 are arranged and/or over-moulded        on the said web 4, about the said protuberance 15. Thus a        connection member is made available.

The said fastening means 17 consist, for example, of a ring allowing thelocking of a corresponding connector 18, about the said protuberance 15.The said connector 18 is equipped with conductors 19 able to beconnected with the said conductors 2 of the fold 16.

That being so, it is possible to define, with the said rigid support 3,the body of the said sub-assembly, that is to say the piece of thelatter which constitutes its structure, which makes it possible tosupport other components, for example mechanical components, and/orgives it its overall shape.

It is possible, particularly, for one of the faces of the said body tobe intended to be oriented towards the user in order to constitute thefront of the said sub-assembly. It is then possible to design the saidflexible web 4 to be in the region of the face opposite the said faceoriented towards the user, that is to say, for example, in the region ofthe said rear face 6.

It should be noted that, according to a particular embodiment, theflexible web 4 is able to accept said electrical and/or electroniccomponents 1 on each of its faces.

That being so, the invention also relates to a dashboard sub-assembly,especially a vehicle-dashboard console, obtained by the manufacturingmethod described above.

As is illustrated in FIG. 7 the said sub-assembly may includevisual-display screens 20 including indicator lamps 5 consisting of thevisual-display means mentioned above.

As is illustrated in FIG. 8, it may also include control panels 21including buttons 5 consisting of the changeover-switching meansmentioned above.

Of course, other implementation methods, within the grasp of the personskilled in the art, could have been envisaged without to any extentdeparting from the scope of the invention.

1. A method of manufacturing a dashboard sub-assembly, comprisingelectrical and/or electronic components connected to electricalconductors and fixed to a rigid support, the method comprising the stepsof: providing a flexible web equipped with the conductors; mounting thecomponents on the web in connection with the conductors; stiffening theweb over molding the web with a material intended to constitute thesupport, wherein at least some of the components are between the web anda rear face of the support that contacts the web; rendering thecomponents that are between the web and the rear face of the supportvisually and/or mechanically accessible from a front face of the supportopposite the rear face, and wherein interface means are defined with atleast some of the components and further comprising a step of modifyingor deforming the material of the support in a region of the componentswith the interface means.
 2. The method according to claim 1, in whichthe material intended to constitute the rigid support is madetranslucent in places to allow light to pass through the support.
 3. Themethod according to claim 1, in which at least one orifice is providedlocally between the front face and the rear face.
 4. A method ofmanufacturing a dashboard sub-assembly that includes electrical and/orelectronic components connected to electrical conductors and fixed to arigid support, the method comprising the steps of: providing a flexibleweb equipped with the conductors; mounting the components on the web inconnection with the conductors; stiffening the web by over molding theweb with a material intended to constitute the support, wherein at leastsome of the components are between the web and a rear face of thesupport that contacts the web; and rendering at least some of thecomponents that are between the web and the rear face of the supportvisually and/or mechanically accessible from a front face of the supportopposite the rear face by providing an orifice between the front faceand the rear face; in which some of the components between the web andthe rear face are changeover-switching means and the orifice is providedin the region of the changeover-switching means.
 5. The method accordingto claim 4, in which switch means are installed in the region of theorifice, the switch means being made able to interact, for thechangeover switching, with a wall of said orifice.
 6. The methodaccording to claim 1, in which at least one part of the components withthe interface means is intended for connection to external electricalcircuits by carrying out the following steps: forming with the materialof the rigid support a protuberance intended to be covered at leastpartly by a fold of the flexible web, establishing an electricalconnection with the conductors in the region of the fold, and arrangingmechanical fastening means on the web about the protuberance.
 7. Amethod of manufacturing a dashboard sub-assembly, comprising electricaland/or electronic components connected to electrical conductors andfixed to a rigid support, the method comprising the steps of: providinga flexible web equipped with the conductors; mounting the components onthe web in connection with the conductors; stiffening the web overmolding the web with a material intended to constitute the support,wherein at least some of the components are between the web and a rearface of the support that contacts the web; and rendering the componentsthat are between the web and the rear face of the support visuallyand/or mechanically accessible from a front face of the support oppositethe rear face; in which a body of the sub-assembly is defined by therigid support.
 8. The method according to claim 7, wherein the web isprovided on a surface of the body opposite a surface of the bodyintended to be oriented towards the user.
 9. A dashboard sub-assemblyobtained by the manufacturing method according to claim 1.